Cable harness breakout assembly method

ABSTRACT

A cable assembly comprises a plurality of electrical or fiber-optic cables, a spacer, and a collar. The cables are arranged lengthwise in a bundle, which includes a segment having a cross-sectional arrangement organized into a plurality of columnar sections of contiguous cables. Each columnar section has at least one cable. The spacer is disposed between adjacent columnar sections of cables and thus forms a dividing line between the adjacent columnar sections. The spacer spans substantially entirely across a cross section of the segment of the bundle in one direction. The collar is disposed entirely around the bundle and the spacer along at least a portion of the segment. The collar is sufficiently tight such that the collar and the spacer cooperate to hold the adjacent columnar sections in substantially fixed relative positions within the cross-section of the bundle.

TECHNICAL FIELD

This disclosure relates generally to cable assemblies and moreparticularly to a cable harness breakout and methods for its assembly.

BACKGROUND

Cables for carrying power, data, control, or other electrical or opticalsignals are often bundled to simplify their handling, connection, orrouting. It is well known to utilize a harness including rings, straps,collars, and/or an outer sheath around a plurality of cables to form andmaintain a bundle comprising those cables. Where the harness ends,typically near the ends of the cables, the cables flare out to allow theindividual cables or sub-bundles to extend to their own destinations.Bundles themselves may be bundled together in a super-bundle.

It is also known in the prior art to have cables of different lengthsexiting a harness, so as to allow sufficient length for each particularcable to reach its desired destination. Typically, the individual cablesare not and cannot be controllably arranged across the cross section ofthe bundle at its end to enable orderly routing of the cables in theproper directions, without, for example, undue crossing of individualcables.

One known structure for bundling cables utilizes a sheath to contain thecables along the majority of the length of the bundle. At the ends ofthe bundle, a collar, such as heat-shrink tubing, is provided justbefore the point of breakout. The individual constituent cables flareout from the heat-shrink collar in varying lengths to reach theirdestinations. Unfortunately, the cables in the bundle are prone torelative slipping and displacement across the cross-sectional area ofthe bundle. That can be attributable to a natural tendency of the cablesto form into a bundle having a circular perimeter outline, especiallywithin a heat-shrink tubing or other constrictive member around thecables. That relative slipping, displacement, and tendency to form acircular bundle can cause the cross-sectional pattern of the cables asthey exit the harness to mismatch their pattern of target destinations.That can be problematic. The results can include (1) undesirablelengthwise stretching or bend strain on the cables; (2) undesirablestrain on the cables' terminating connectors and their destinationconnector ports; (3) greater probability of connecting a cable to awrong destination; (4) disorderly and unsightly crossing of cables; (5)extra time and effort for a person to connect the cables to theirdestinations; and even (6) inability to connect a cable to itsdestination.

SUMMARY

A cable assembly comprises a plurality of electrical or fiber-opticcables, a spacer, and a collar. The cables are arranged lengthwise in abundle, which includes a segment having a cross-sectional arrangementorganized into a plurality of columnar sections of contiguous cables.Each columnar section has at least one cable. The spacer is disposedbetween adjacent columnar sections of cables and thus forms a dividingline between the adjacent columnar sections. The spacer spanssubstantially entirely across a cross section of the segment of thebundle in one direction. The collar is disposed entirely around thebundle and, the spacer along at least a portion of the segment. Thecollar is sufficiently tight such that the collar and the spacercooperate to hold the adjacent columnar sections in substantially fixedrelative positions within the cross-section of the bundle.

A method assembles a plurality of electrical or fiber-optic cables intoa cable harness breakout. Segments of a first subset of the plurality ofcables are arranged into a contiguous first group. A substantially rigidspacer is placed along a side of the first group. Segments of a secondsubset of the plurality of cables are arranged into a contiguous secondgroup, and a side of the second group is placed along the spacer, sothat the first group and the second group have an arrangedconfiguration. The first group, the spacer, and the second group aresecured together in the arranged configuration.

A cable bundle breakout harness comprises a plurality of cables, a setof spacers, and a collar. Coextensive segments of the cables arearranged in a rectangular-array having N rows and M columns, where M andN are natural numbers (i.e., non-zero positive integers). The set ofspacers demark the interior boundaries of the N rows. The collarsurrounds the cables and the set of spacers.

Another cable harness breakout is near an end of a bundle of electricaland/or fiber-optic cables. The cable harness breakout comprises meansfor arranging coextensive segments of the cables into a cross-sectionalarrangement having a regular, desired configuration. The cable harnessbreakout also comprises means for holding the coextensive segments ofthe cables in substantially fixed relative positions in the desiredconfiguration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a cable assembly, according to one embodiment.

FIG. 2 is an enlarged cross-section view of the cable assembly of FIG. 1taken along line 2—2 of FIG. 1.

FIGS. 3A, 3B, and 3C are respective front, side, and top views of aspacer utilized in the cable assembly of FIG. 1.

FIGS. 4 and 5 are pictorial views of alternate cable assemblies invarious uses.

FIG. 6 is a pictorial view of the cable assembly of FIG. 1 during astate of partial assembly.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to the above-listed drawings, this section describesparticular embodiments and their detailed construction and operation. Asone skilled in the art will appreciate, certain embodiments are capableof achieving certain advantages over the known prior art, including someor all of the following: (1) reduced lengthwise stretching and bendstrain on the cables; (2) reduced strain on the cables' terminatingconnectors and their destination connector ports; (3) less chance ofconnecting a cable to a wrong destination; (4) more orderly andaesthetically appealing appearance of cables exiting the bundle harness;(5) improved ability to connect a cable to its destination; and (6)labor savings when connecting the cables to their destinations. Theseand other advantages of various embodiments will be apparent uponreading the following.

FIG. 1 is a plan view of a cable assembly 100, according to oneembodiment. The cable assembly 100 comprises sixteen individual cables105 bundled in a sheath 110 (not shown to scale). The number of cablesmay be more or less; sixteen cables are shown only as an illustration.The sheath 110 is an elongate, generally tubular-shaped memberencircling the bundle of cables 105 along a major portion of the bundlelength. The sheath 110, which is optional, may be a mesh of plasticfibers, fabric, or any other sheet material that can be formed in aclosed, generally tubular shape. At the end of each cable 105 is aconnector 115. Although the connector 115 is not required in all cases,it is typically present. Optionally, around each cable 105 is label 120,which may be used, for example, for identifying each cable 105. Thesixteen cables 105 in FIG. 1 are labeled A, B, C, . . . , P.

Along a segment of the bundle of cables 105 in the cable assembly 100,typically near the cables' end is a breakout harness 122, from which thecables 105 breakout from the bundle. The breakout harness 122 isoptionally surrounded by a collar 125. The collar 125 may be heat shrinktubing, for example. The collar 125 can be bonded to the sheath 110 byhaving the collar 125 surround a portion of the end of the sheath 110and by providing an adhesive therebetween. Other means for attaching thecollar 125 and the sheath 110 are possible, if such an attachment isdesired.

FIG. 2 is an enlarged cross-section view of the cable assembly 100within the collar 125, taken along the line 2—2 of FIG. 1. Thus, FIG. 2shows the cross section of the bundle of cables 105 near the point ofbreakout. As shown in FIG. 2, the sixteen cables 105 are arranged in asquare four-by-four array. Although other arrangements are possible, thecables 105 within the collar 125 can be arranged in a pattern that isroughly congruent or readily mapped to the pattern in which their endsare desirably directed. Typically that pattern is rectangular, a factdictated at least in part by the nature of the equipment to which thecables are to be connected. For example, the cables 105 labeled A–D,which extend farthest to the left in FIG. 1, are arranged in theleftmost column in FIG. 2. Similarly, the cables 105 labeled E–H, I–L,and M–P respectively extend lesser distances away from the breakoutharness sheath 125 and are respectively arranged in separate columnsfrom left to right in FIG. 2. In this case, the cables 105 labeled A–Dhave generally longer extension lengths (measured from the breakoutharness 122 to the respective connector 115) than those labeled E–H,which are longer than those labeled I–L, which are longer than thoselabeled M–P.

Also shown in FIG. 2 are a number of spacers 135, extending along thesides of each column of cables 105 within the collar 125. The collar 125aids in holding the spacers 135 and the cables 105 together in a desiredarrangement. An illustrative spacer 135 is shown in perspective views inFIG. 3. The spacers 135 can be formed of plasticized cardboard, plastic,wood, metal, or any other suitable material. The spacers 135 aredimensioned so as to approximately match the dimensions of the desiredcross-sectional arrangement of the cables 105 within the collar 125. Theheight and width of the spacer 135 is typically dictated by the size andnumber of cables in the bundle. The spacers 135 ideally have a thicknesssufficient to be substantially rigid and to resist breaking. The spacers135 may be more or less flexible to suit a particular use. The spacer135 is shown as a contiguously solid piece, but it need not be. Forexample, the spacer 135 may be formed with holes in its body.

The spacers 135 form and maintain the cables 105 in a desiredcross-sectional arrangement, such as the square array arrangementillustrated in FIG. 2, within the breakout harness sheath 125. In otherwords, the spacers 135 partition the bundle into a plurality of sectionsof contiguous cables. As illustrated in FIG. 2, the sections areone-by-four columns. Other arrangements and section shapes are possible.For instance, the spacers 135 may be oriented horizontally, rather thanvertically, so as to partition the space within the collar 125 intorows, rather than columns. In fact, the difference between rows andcolumns is one of perspective, not substance.

Furthermore, straight planar spacers in both the vertical and horizontalcan be used together. One method for doing so is to provide notches onthe spacers lengthwise (horizontally in FIG. 3) of a width slightlygreater than the thickness of the spacer, such that a notch of ahorizontal spacer cooperates with a notch of a vertical spacer in amating relationship. For example, a such pair of mating horizontal andvertical spacers could be-utilized to partition the sixteen cables 105in FIG. 2 into four two-by-two sections.

Also shown in FIG. 2 are outermost spacers 137. Although the outermostspacers 137 are optional, they provide additional structural stability.They may be omitted when, for example, the collar 125 is sufficientlystrong by itself or the number of cables is small.

Certain of the other spacers 135 illustrated in FIG. 2 can be omitted.For example, it is not necessary that the columns formed by the spacers135 be only one cable wide; thus, for example, the second and fourthspacers 135 can be omitted, so as to form two columns two cables inwidth.

Moreover, the spacers 135 may have protrusions along its front and/orback faces. Such protrusions can advantageously be positioned tocorrespond to and fill (at least partially) cavities 138 formed alongthe side edges of two round cables when they are placed atop oneanother. A desirable cross-sectional shape of such a protrusion istriangular, as viewed in FIG. 2, preferably with slightly concave wallsto best match the cross-sectional shape of the cables 105 along thecavities 138 filled by the protrusions.

Indeed, as an alternative to the interior spacers 135 shown in FIG. 2,one could utilize three separate pieces having an approximate diamondshape. One such piece could be set within the cavity formed by fourcables 105 arranged two-by-two (e.g., the cables 105 labeled A, B, F,and E). Preferably, such pieces would have generally concave sides tobest match the cross-section shape of the cavity they are intended tofill.

As another alternative, each cable 105 in the pertinent segment of thebundle could be fitted with an individual collar having an insidesidewall that is circular in cross section, so as to conform to thecable 105, and an exterior cross-sectional perimeter that is generallysquare or rectangular. The cables 105 outfitted with such collars couldthen be stacked like blocks in a desired arrangement and held togetherwith an interlocking mechanism and/or an outside wrap, such as thecollar 125. In that case, the set of such collars constitute thespacers.

In still another alternative, the set of spacers together may be formedin place about and between the cables 105, such as by molding orextrusion. In that case, the collar 125 may not be necessary.

Returning to the case in which the spacers are sheet-like members, thespacers need not be straight planar sections; spacers may be curvedsegments or even closed tubular pieces. For example, a set of spacersmay be concentric cylindrically shaped pieces.

Although the spacers 135 have been illustrated herein as separatepieces, they may take other forms or may be joined. For example, thefive vertical spacers 135 shown in FIG. 2 may be joined to a horizontalspine along the top or bottom of the bundle. Such a spine, which actslike a mechanical “backplane,” can optionally be formed of a flexiblematerial to facilitate access to the columnar-shaped sections duringassembly.

As one can tell from the variety of forms that the spacers can take, theterm “spacer” is a broad term referring to any substantially rigidmaterial or collection of pieces positioned between cables to help alignsections of cables in substantially fixed relative positions.

FIGS. 4 and 5 are perspective views of alternative cable assemblies 200and 300, respectively. In FIG. 4, the connectors 115 are engaged inmating connector ports 140 distributed across a surface 145 in arectangular six-by-two (or, alternatively, three-by-four) arrangement.Thus, the cable assembly 200 near the point of breakout advantageouslyis consistent with that arrangement of target connector ports 140 on thesurface 145. For example, a number of spacers can be utilized topartition the exiting cables 105 in a corresponding six-by-twocross-sectional arrangement. As another example, spacers can be utilizedto partition the exiting cables in three columns of four cables, witheach column supplying cables 105 to either the left, middle, or righttwo-by-two set of four connector ports 140. The latter arrangement maybe more stable, as it more closely conforms to the natural tendency ofthe cables to bunch together as closely as possible.

In FIG. 5, the cable assembly 300 is shown with its connectors 115 heldin place in a desired arrangement by a ganged holder 155. The cableassembly 300, like the one in FIG. 4, utilizes spacers to divide thecross-section of the bundle of exiting cables into sections that in somesense match or more closely match the spatial layout of the cables 105entering the ganged holder 155.

The cable assemblies 200 and 300 are examples of a bundle of cablesapproaching a flat surface at a parallel or somewhat parallel angle andthe cable destinations being distributed across the face of thatsurface. In that case, the individual cables extending out the breakoutpoint bend to reach their destinations. In that case, the cables on theinterior side of the bend are desirably directed to targets nearest tothe approach side, while cables progressively toward the other side ofthe bundle are desirably directed to targets more distant from theapproach side. Thus, the cables near the approach side of the bundle(the side with the smaller turn radius) typically require the shortestextension length to reach their targets, while the extension lengthsbecome progressively greater toward the opposite side of the bundle (theside with the larger turn radius). The cable assembly 300 is especiallyuseful when the cables 105 are require to bend by a known amount. Inthat case, the breakout harness 122 holds the cables 105 in a desiredarrangement on one end, the ganged holder 155 holds the cables 105 in adesired arrangement on the other end, and the extension lengths can becut precisely to accommodate the bend.

In another expected use, a cable bundle is designed to approach a flatsurface (e.g., surface 145), in which the cable destinations (e.g.,connector ports 140) lie, perpendicularly. In that case, the bundle endnear the breakout point is desirably designed such that cables goingfurthest to the right are located near the furthest right side of thebundle, cables going furthest to the left are located near the furthestleft side of the bundle, etc. In that case, cables near the periphery ofthe bundle may require a greater extension length to reach theirdestinations than would the cables near the center of the bundle,assuming that the bundle approaches the surface near the center of thepattern of destinations.

FIG. 6 is a pictorial view of a section of the cable assembly 100 duringa state of partial assembly. More specifically, FIG. 6 shows the cableassembly 100 in the vicinity of its breakout harness 122 before thecollar 125 has been attached. As can be seen, the breakout harness 122comprises five spacers 135 dividing the set of cables 105 into fourcolumns and holding the cables 105 in a four-by-four cross-sectionalarrangement. Thus, as illustrated, the spacers 135 and columns of cables105 have been laid out in an alternating pattern, beginning with anoutermost spacer 137 on one side, a column of four cables, another(interior) spacer 135, another column of four cables, and so on,concluding with a final outermost spacer 137 on the far opposite side.The sandwiched bundle arrangement of cables 105 and spacers 135 are heldtogether by an adhesive tape 165 wrapped around the outermost spacers137 and along the top and bottom of the bundle. The adhesive tape 165can be, for example, made of a heat-resistant material, such as KAPTONbrand polyimide film made by E.I. du Pont de Nemours and Company. Thepartially assembled breakout harness 122, as illustrated in FIG. 6, canthen be surrounded by the collar 125, such as a heat-shrink tube, whichis then heated to shrink and form around the cables 105, spacers 135.Furthermore, on the bundled side of the breakout harness 122, the cables105 can be encased by the sheath 110. A portion of the sheath 110 can beextended under the heat-shrink tube before it is shrunk, and a layer ofadhesive material can be provided on the portion of the sheath 110 underthe heat-shrink tube in order to secure the sheath 110 and theheat-shrink tube together.

Although the partially assembled cable assembly 100 illustrated in FIG.6 is shown with vertically oriented spacers 135, they could just aseasily be oriented horizontally. In some sense, the vertical-horizontaldistinction is an arbitrary matter of perspective.

The terms and descriptions used herein are set forth by way ofillustration only and are not meant as limitations. Those skilled in theart will recognize that many variations can be made to the details ofthe above-described embodiments without departing from the underlyingprinciples of the invention. For example, although the invention isdescribed with reference to electrical cables, that is done only tofacilitate easy understanding; the concepts described herein are equallyapplicable to cables of any type (e.g., fiber-optic, hydraulic, to namejust a couple). The scope of the invention should therefore bedetermined only by the following claims, and their equivalents, in whichall terms are to be understood in their broadest reasonable sense unlessotherwise indicated.

1. A method for assembling a plurality of electrical cables into a cableharness breakout, the method comprising: arranging segments of a firstsubset of the plurality of cables into a contiguous first groupaccording to an array configuration; placing a substantially rigidspacer along a side of the first group; arranging segments of a secondsubset of the plurality of cables into a contiguous second group andplacing a side of the second group along the spacer, so that the firstgroup and the second group are arranged in the array configuration; andforming the cable harness assembly by wrapping the first group, thespacer, and the second group together with a collar in the arrangedarray configuration while the spacer maintains the array configuration.2. The method of claim 1, wherein the first and the second groups ofcables are rows of N cables each, where N is a natural number.
 3. Themethod of claim 1, further comprising: placing spacers on opposing sidesof the first and second groups of cables.
 4. The method of claim 1,wherein the spacer has a shape that is generally a sheet.
 5. The methodof claim 1, further comprising: holding the plurality of cables in thearranged array configuration using the collar and the spacer after thecable harness assembly is formed.
 6. The method of claim 5, wherein thesurrounding step comprises: placing a heat-shrink tube around the firstgroup, the spacer, and the second group in the arranged configuration;and heating the heat-shrink tube so as to constrict around the firstgroup, the spacer, and the second group in the arranged configuration.7. The method of claim 1, wherein the step of placing the substantiallyrigid spacer is performed before the step of arranging segments of thesecond subset of the plurality of cables into the contiguous secondgroup and placing a side of the second group along the spacer.
 8. Amethod for assembling a cable harness breakout, the method comprising:arranging a plurality of contiguous cables, at least coextensivesegments of the cables including a cross section in a rectangular arrayhaving N rows and M columns; demarking the interior boundaries of the Nrows with a set of spacers, wherein the spacers have a shape that isgenerally a sheet and lie in a plane generally parallel to thelengthwise direction of the cables in the segment; and wrapping theplurality of contiguous cables and the spacers using a collar withsufficient tightness to hold the plurality of cables in substantiallyfixed relative positions within the cross-section of the cable harnessbreakout.
 9. The method of claim 8, wherein the set of spacers comprisesN−1 separate pieces.
 10. The method of claim 8, further comprisingdemarking the exterior boundaries of the topmost and bottommost rowsusing two spacers.
 11. The method of claim 8, wherein at least one ofthe spacers is a single, unitary piece.
 12. The method of claim 8,wherein the spacers are approximately rectangular.
 13. The method ofclaim 8, wherein the spacers and the collar are separate pieces.
 14. Themethod of claim 8, wherein at least one of the spacers is a contiguouslysolid piece.
 15. The method of claim 8, wherein at least one of thespacers is formed of a plasticized cardboard.
 16. The method of claim 8,wherein the collar comprises a heat-shrink tube.
 17. The method of claim8, further comprising surrounding the plurality of cables and thespacers using a piece of adhesive tape before surrounding at least someof the cables and the spacers using a collar.
 18. A method forassembling a plurality of cables into a cable harness breakout, themethod comprising: arranging a first subset of the plurality of cablesinto a contiguous first group; placing a substantially rigid plate alonga side of the first group; arranging a second subset of the plurality ofcables into a contiguous second group and placing a side of the secondgroup along the rigid plate, wherein the substantially rigid plate inbetween the contiguous first and second groups; organizing the first andsecond groups of cables into an array configuration; and forming thecable harness assembly by wrapping and compressing the first group, theplate, and the second group together using a heat shrink tube while theplate maintains the array configuration.